Hose construction, coupling therefor and methods of making the same

ABSTRACT

A hose construction, coupling therefor and methods of making the same are provided, the hose construction comprising a tubular hose and a coupling secured to one end of the tubular hose, the coupling having an insert disposed in the one end of the tubular hose and being radially outwardly expanded into sealing relation with an inner corrugated hose of the tubular hose, the insert having an outer peripheral surface defined by a plurality of outwardly directed projections with recesses therebetween, the projections of the insert being respectively received in recesses of the inner hose and projections of the inner hose being respectively received in the recesses of the insert whereby the interior of the tubular hose is substantially sealed to the interior of the coupling, the projections of the insert each having a substantially flat outer surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation patent application of its copendingparent patent applicaton, Ser. No. 993,196, filed Dec. 18, 1992, nowabandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a new hose construction and to a new couplingtherefor as well as to a new method of making such a hose constructionand a new method of making such a coupling.

2. Prior Art Statement

It is known to provide a hose construction comprising a tubular hosehaving an inner peripheral surface means and an outer peripheral surfacemeans, and a coupling secured to one end of the tubular hose, the innerperipheral surface means of the tubular hose comprising an innercorrugated hose made of polymeric material and having inwardly convexprojections with recesses therebetween and extending from the one end ofthe tubular hose to the other end thereof, the coupling having an insertmeans disposed in the one end of the tubular hose and being radiallyoutwardly expanded into sealing relation with the inner corrugated hose,the insert means having an outer peripheral surface means defined by aplurality of outwardly directed projections with recesses therebetween,the projections of the insert means being respectively received in therecesses of the inner hose and the projections of the inner hose beingrespectively received in the recesses of the insert means whereby theinterior of the tubular hose is substantially sealed to the interior ofthe coupling, the projections of the insert means each having asubstantially convex outer surface. For example, see the U.S. Pat. No.5,129,686 to Sanders et al.

SUMMARY OF THE INVENTION

It is one of the features of this invention to provide a new hoseconstruction of the type set forth in the aforementioned U.S. Pat. No.5,129,686 to Sanders et al, and wherein the insert means of the couplingis uniquely formed.

In particular, it was found according to the teachings of this inventionthat the insert means for the coupling can be made with projections witheach having a substantially flat outer surface rather than the matingconcave outer surface as in the aforementioned U.S. Pat. No. 5,129,686to Sanders et al, and still provide effective sealing with the innercorrugated hose of the tubular hose of the hose construction even thoughthose projections do not extend all the way to the roots of the recessesof the inner corrugated hose of the tubular hose whereby the insertmeans can be made of metallic material and have a larger inside diameterso as to be less likely to crack when radially outwardly expanded intosealing relation with the inner corrugated hose of the tubular hoseconstruction.

For example, one embodiment of this invention provides a hoseconstruction comprising a tubular hose having an inner peripheralsurface means and an outer peripheral means, and a coupling secured toone end of said tubular hose, the inner peripheral surface means of saidtubular hose comprising an inner corrugated hose made of polymericmaterial and having inwardly convex projections with recessestherebetween and extending from the one end of the tubular hose to theother end thereof, the coupling having an insert means disposed in theone end of the tubular hose and being radially outwardly expanded intosealing relation with the inner corrugated hose, the insert means havingan outer peripheral surface means defined by a plurality of outwardlydirected projections with recesses therebetween, the projections of theinsert means being respectively received in the recesses of the innerhose and the projections of the inner hose being respectively receivedin the recesses of the insert means whereby the interior of the tubularhose is substantially sealed to the interiof of the coupling, theprojections of the insert means each having a substantially flat outersurface.

Accordingly, it is an object of this invention to provide a new hoseconstruction having one or more of the novel features of this inventionas set forth above or hereinafter shown or described.

Another object of this invention is to provide a new method of makingsuch a hose construction, the method of this invention having one ormore of the novel features of this invention as set forth above orhereinafter shown or described.

Another object of this invention is to provide a new coupling for such ahose construction, the coupling of this invention having one or more ofthe novel features of this invention as set forth above or hereinafrershown or described.

Another object of this invention is to provide a new method of makingsuch a coupling, the method of this invention having one or more of thenovel features of this invention as set forth above or hereinafter shownor described.

Other objects, uses and advantages of this invention are apparent from areading of this description which proceeds with reference to theaccompanying drawings forming a part thereof and wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of the new hose construction ofthis invention.

FIG. 2 is an enlarged cross-sectional view of a part of the new couplingof this invention that is utilized to form the hose construction of FIG.1.

FIG. 3 is an exploded cross-sectional view illustrating the three partsof the new coupling of this invention utilized to form the hoseconstruction of FIG. 1.

FIG. 4 is a view similar to FIG. 3 and illustrating the parts of FIG. 3in their assembled relation before the parts are secured together.

FIG. 5 is a view similar to FIG. 4 and illustrates how the parts of FIG.4 are secured together.

FIG. 6 is an enlarged fragmentary cross-sectional view of the tubularhose of the hose construction of FIG. 1.

FIG. 7 is an exploded view of the coupling and hose of the hoseconstruction of FIG. 1 before the same are telescoped together, FIG. 7being partially in cross section.

FIG. 8 is a view similar to FIG. 7 and illustrates the coupling and hosetelescoped together before the coupling is secured to the end of thehose.

FIG. 9 is a view similar to FIG. 8 and illustrates how the coupling issecured to the end of the hose.

FIG. 10 is an enlarged fragmentary cross-sectional view of the couplingand hose in the secured relation of FIG. 9.

FIG. 11 is an exploded fragmentary view illustrating another hoseconstruction of this invention and how the same is adapted to becouplied to a T-shaped connector that is adapted to have the otherbranch thereof closed off by an end cap means, FIG. 11 being partiallyin cross section.

FIG. 12 is an exploded fragmentary view illustrating the other end ofthe hose construction of FIG. 11 and being adapted to be coupled to anadaptor, FIG. 12 being partially in cross section.

FIG. 13 is an exploded fragmentary view similar to FIG. 11 andillustrates how the one branch of the T-shaped connector is adapted tobe interconnected to an adaptor rather than to an end cap as in FIG. 11,FIG. 13 being partially in cross section.

FIG. 14 is an exploded fragmentary view similar to FIG. 12 andillustrates how the end of the hose construction is adapted to becoupled to an end cap means rather than to an adaptor as in FIG. 12,FIG. 14 being partially in cross section.

FIG. 15 is an exploded fragmentary view illustrating the T-connector ofFIG. 11 and the exploded parts of the end of the hose constructionbefore the coupling is completed and before the end of the hose has beentelescoped within the coupling, FIG. 15 being partially in crosssection.

FIG. 16 is a cross-sectional view of the T-shaped connector of FIG. 15and is taken in the direction of the arrows 16--16 of FIG. 15.

FIG. 17 is a view similar to FIG. 16 and illustrates how the rotatablecoupling of the T-connector is wired thereon.

FIG. 18 is an enlarged fragmentary cross-sectional view of a portion ofthe coupling part illustrated in FIG. 15 and is taken generally in thedirection of the arrows 18--18 of FIG. 15.

FIG. 19 is an enlarged fragmentary cross-sectional view of the end ofthe hose construction illustrated in FIG. 11.

FIG. 20 is a view similar to FIG. 8 and illustrates another hoseconstruction of this invention.

FIG. 21 is a view similar to FIG. 19 and illustrates another hoseconstruction of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the various features of this invention are hereinafter illustratedand described as being particularly adapted to provide a hoseconstruction for conveying gasoline and like volatile liquidstherethrough, it is to be understood that the various features of thisinvention can be utilized singly or in various combinations thereof toprovide a hose construction for conveying other fluids therethrough forother types of apparatus as desired.

Therefore, this invention is not to be limited to only the embodimentsillustrated in the drawings because the drawings are merely utilized toillustrate one of the wide variety of uses of this invention.

Referring now to FIG. 1, the new hose construction of this invention isgenerally indicated by the reference numeral 30 and comprises a tubularhose 31 and a coupling 32 secured to one end 33, FIG. 7, of the hose 31in a manner hereinafter set forth. Of course, a like coupling 32 or anyother suitable structure can be secured to the other end (not shown) ofthe hose 31, if desired.

As previously set forth, one of the features of this invention is toprovide a uniquely formed structure on an insert means of the coupling32 so as to uniquely interconnect the coupling 32 of this invention tothe hose 31 and still provide for a fluid sealed relation between theinteriors thereof in substantially the same manner as set forth in theaforementioned U.S. Pat. No. 5,129,686 to Sanders et al, whereby thisU.S. patent is being incorporated into this disclosure by this referencethereto.

Such unique means for providing such sealed relation is necessitated bythe unique construction of the hose 31 which is fully disclosed andclaimed in the U.S. Pat. No. 5,089,074 to Winters et al, whereby thisU.S. patent is also being incorporated into this disclosure by thisreference thereto.

Therefore, only the details of the hose 31 and the coupling 32 that arebelieved to be necessary to understand the features of this invention informing the hose construction 30 of this invention will now be setforth.

As illustrated in FIG. 6 the hose 31 comprises an inner corrugated hose34 formed of any suitable polymeric material and having a plurality ofoutwardly convex projections 35 with concave recesses 36 therebetweenand extending from one end of the hose 31 to the other end thereof, atube 39 of any suitable polymeric material and extending in a generallystraight line manner from projection 35 to projection 35 as illustratedin FIG. 6, an outer sleeve 40 of any suitable reinforcing materialdisposed in telescoped relation on the tube 39, and an outer layer 41 ofany suitable polymeric material that will provide a protection for thesleeve 40 of reinforcing material and also to tend to prevent any liquidthat is conveyed through the flexible hose 31 from permeating to theexterior thereof, such as gasoline and the like.

The inner corrugated hose 34 has a plurality of inwardly convexprojections 37 with concave recesses 38 therebetween, the innerprojections 37 and recesses 38 defining the interior 34' of the hose 31.

The coupling 32 of this invention for sealing to the inner peripheralsurface means 34' of the hose 31 is formed of any suitable metallicmaterial and comprises a tubular body member 42 having a portion 43disposed intermediate two annular recesses 44 and 45 thereof andrespectively into which ends 47 and 48 of a rotatable nut 49 and anouter sleeve 50 are radially inwardly deformed in the manner illustratedin FIG. 5, the nut 49 being rotatable relative to the body member 42while the outer sleeve 50 is interconnected to the body member 42 insubstantially a non-rotatable manner therewith.

The body member 42 of the coupling 32 has a sleeve-like insert means 51provided with an internal peripheral surface means 52 and an outerperipheral surface means 53 and is adapted to be telescoped within theend 33 of the hose 31 in the manner illustrated in FIGS. 7 and 8 andthen be radially outwardly expanded in the manner indicated by thearrows in FIG. 9 to not only interconnect the coupling 32 to the end 33of the hose 31, but to also seal the internal peripheral surface 52 ofthe coupling 32 to the internal peripheral surface means 34' of the hose31 so as to prevent fluid leakage therebetween as liquid is conveyedthrough the hose construction 30 for the reasons fully set forth in theaforementioned U.S. Pat. No. 5,129,686 to Sanders et al.

The body member 42 of the coupling 32 has the internal peripheralsurface means 52 thereof substantially smooth throughout the entirelength thereof so as to define a cylindrical configuration that will notcause the outer peripheral surface means 53 of the insert means 51 toflatten when a suitable expanding tool is engaged against the surfacemeans 52 in a manner well known in the art. However, the outerperipheral surface means 53 of the insert 51 is defined by a pluralityof outwardly directed projections 54 with concave recesses 55therebetween so that when the same is inserted in the end 33 of the hose31, the inward projections 37 of the hose 31 will be received in therecesses 55 while the projections 54 of the insert means 51 will bereceived in the recesses 38 of the inner hose 34 of the hose 31.

It was found according to the teachings of this invention that whenforming the outer projections on the insert means of the coupling to beconvex in the manner set forth in FIGS. 16-18 of the aforementioned U.S.Pat. No. 5,129,686 to Sanders et al, the upper third of such crests didnot contribute to the sealing effect with the hose 31 as there was nocontact with the roots of the valleys 38 of the hose 31 and thereforethis additional height of the crests or projections on the insert meanswas not needed for sealing.

Therefore, it was further found according to the teachings of thisinvention that the projections 54 of the insert means 51 could be cutoff or truncated in order to define flat outer surfaces 56 thereof. Thispermitted the outside diameter of the insert means 51 to be the sameoutside diameter as the prior known insert means where the outsidediameter extended all the way to the apexes of the rounded creststhereof whereas with the insert means 51 of this invention, the outsidediameter would extend to the flat surfaces 56 and this permitted theinside diameter that defines the internal peripheral surface 52 thereofto be larger than in the prior known coupling structure. Accordinglythis reduces the amount of expansion of the insert means 51 radiallyoutwardly during the coupling operation with the end 33 of the hose 31while maintaining positive sealing with the internal peripheral surfacemeans 34' of the hose 31 and this, in turn, reduces cost, reducesassembly time and reduces possibilities of cracking of the insert means51.

Therefore, it can readily be seen in FIG. 10 of applicant's drawingsthat full sealing of the external peripheral surface means 53 of insertmeans 51 is provided with the internal peripheral surface means 34' ofthe hose 31 even though the projections 54 of the insert means 51 do notreach the roots 57 of the valleys or recesses 38 of the hose 31 duringthe radially outward expansion of the insert means 51 that also placesan outer peripheral surface 58 of the hose 31 into engagement with aninternal peripheral surface 59 of the sleeve 50.

While any suitable dimensions can be provided for the insert means 51 ofthis invention, in one working embodiment thereof that was utilized forcoupling to a hose 31 that had the same dimensions as set forth in theone working embodiment thereof in the aforementioned U. S. Pat. No.5,129,686 to Sanders et al, wherein the inside diameter of the hose 31is approximately 1.500 of an inch with the distance between the apexesof the projections 37 being approximately 0.246 of an inch, the insertmeans 51 of this invention before the radially outward expansion thereofhas an inside diameter of approximately 1.326 to 1.336 inches and anoutside diameter of approximately 1.520 to 1.53 inches with the concaverecesses 55 being defined by a radius of approximately 0.080 to 0.090 ofan inch so that the depth of the recesses 55 is approximately 0.041 ofan inch. Thus, it can be seen that in such one working embodiment of theinsert means 51 of this invention the projections 54 of the insert means51 each has a transverse cross-sectional length that is less than thetransverse cross-sectional length of each of the recesses 55.

While the projections and recesses of the hose 31 and the insert means51 have been previously illustrated and described as each being annular,it is to be understood that each could be disposed in a helical path asfully set forth in the aforementioned U.S. Pat. No. 5,129,686 to Sanderset al, and as illustrated in FIG. 20 wherein another hose constructionof this invention is generally indicated by the reference numeral 31Aand parts thereof that are similar to the parts of the hose construction30 previously described are indicated by like reference numeralsfollowed by the reference letter "A".

Another hose construction of this invention is generally indicated bythe reference numeral 30B in FIGS. 11-19 and parts thereof that aresimilar to the parts of the hose construction 30 previously describedare indicated by like reference numerals followed by the referenceletter "B".

It can be seen that the coupling 32B of FIGS. 11-19 is substantiallyidentical to the coupling 32 of FIGS. 1-10 except that an outer end 60thereof does not have the rotatable nut 49 thereon and the same isprovided with external threads 61 which are adapted to couple intointernal threads 62 of a rotatable sleeve 63 that is rotatably mountedon a branch 64 of a T-connector 65 which has a like sleeve 63 mounted onthe opposite branch 64' thereof as illustrated in FIGS. 11 and 15.

In addition, a metallic annular beveled sealing member 66 is adapted toseal an inwardly beveled surface 67 of the body member 42B to an outerbeveled surface 68 of the branch 64 of the T-connector 65 all in amanner well known in the art.

As is also well known in the art, the sleeves 63 are adapted to berotatably mounted to the branches 64 and 64' of the T-connector 65 by awire means 69 fed through an opening 70 in the respective sleeve 63 andreceived in cooperating grooves 71' and 72' formed respectively in theinternal surface means of the sleeve 63 and internal surface means ofthe branch 64 as illustrated in FIGS. 16 and 17.

The sleeves 63 of the T-connector 65 can be utilized to couple to hoseconstructions 30B of this invention at each branch 64 and 64' thereof orone of the sleeves 63 can be utilized to interconnect to an end capmeans 71 as illustrated in FIG. 11 or to an adaptor means 72 asillustrated in FIG. 13 wherein an externally threaded outlet projection73 thereof can interconnect to a downed size tubular structure asdesired.

Similarly, the other end of the hose construction 30B of this inventionas illustrated in FIG. 12 can be interconnected to a sleeve 74 on anadaptor 75 that has an enlarged externally threaded projection 76 forcoupling to larger tubular means as desired or can be coupled to asleeve 77 of an end cap means 78 as illustrated in FIG. 14.

Thus, it can be seen that the hose construction 30B of this invention issubstantially identical to the hose construction 30 previously set forthand while the same has annular projections and recesses not only on theinsert means 42B thereof but also on the hose 31B thereof, the samecould be all formed helical in the manner fully illustrated in FIG. 21wherein another hose construction of this invention is generallyindicated by the reference numeral 30C and parts thereof that aresimilar to the parts of the hose construction 30B previously describedare indicated by like reference numerals followed by the referenceletter "C".

Therefore, it can be seen that this invention not only provides a newhose construction and a new method of making such a hose construction,but also this invention provides a new coupling and a new method ofmaking such a coupling.

While the forms and methods of this invention now preferred have beenillustrated and described as required by the Patent Statute, it is to beunderstood that other forms and method steps can be utilized and stillfall within the scope of the appended claims wherein each claim setsforth what is believed to be known in each claim prior to this inventionin the portion of each claim that is disposed before the terms "theimprovement" and sets forth what is believed to be new in each claimaccording to this invention in the portion of each claim that isdisposed after the terms "the improvement" whereby it is believed thateach claim sets forth a novel, useful and unobvious invention within thepurview of the Patent Statute.

What is claimed is:
 1. In a hose construction comprising a tubular hosehaving an inner peripheral surface means and an outer peripheral surfacemeans, and a coupling secured to one end of said tubular hose, saidinner peripheral surface means of said tubular hose comprising an innercorrugated hose made of polymeric material and having inwardly convexprojections with recesses therebetween and extending from said one endof said tubular hose to the other end thereof, said coupling having aninsert means disposed in said one end of said tubular hose and beingradially outwardly expanded into sealing relation with said innercorrugated hose, said insert means having an outer peripheral surfacemeans defined by a plurality of outwardly directed projections withrecess therebetween, said projections of said insert means beingrespectively received in said recesses of said inner hose and saidprojections of said inner hose being respectively received in saidrecesses of said insert means whereby the interior of said tubular hoseis substantially sealed to the interior of said coupling, said convexprojections of said hose respectively having apexes that defined aninside diameter of said hose of approximately 1.500 inches and a pitchof said convex projections of approximately 0.246 of an inch before saidinsert means was radially outwardly expanded, said insert meanscomprising a tubular metallic sleeve that is formed to define said outerperipheral surface means thereof, the improvement wherein saidprojections of said sleeve each has a substantially flat outer surfaceand defined an outside diameter of said sleeve of approximately 1.515inches before said sleeve was radially outwardly expanded, said sleevehaving defined an inside diameter thereof of approximately 1.331 of aninch before said sleeve was radially outwardly expanded, said recessesof said sleeve each having had a depth of approximately 0.041 of an inchbefore said sleeve was radially outwardly expanded.
 2. A hoseconstruction as set forth in claim 1 wherein said recesses of saidsleeve each has a substantially concave outer surface.
 3. A hoseconstruction as set forth in claim 1 wherein said projections of saidsleeve each has a transverse cross-sectional configuration of a certainlength and said recesses of said sleeve each has a transversecross-sectional configuration of a predetermined length that isdifferent than said certain length.
 4. A hose construction as set forthin claim 1 wherein said projections of said inner hose and said sleeveare respectively annular and are respectively disposed substantiallytransverse to the longitudinal axis of said hose construction.
 5. A hoseconstruction as set forth in claim 1 wherein said projections of saidinner hose and said sleeve respectively extend in a helical path aboutthe longitudinal axis of said hose construction.
 6. A hose constructionas set forth in claim 1 wherein said recesses of said sleeve each had asubstantially concave outer surface defined by a radius of approximately0.085 of an inch before said sleeve was radially outwardly expanded. 7.A hose construction as set forth in claim 1 wherein said tubular hosehas an outer peripheral surface means, said coupling having an outermetallic tubular member telescopically disposed over said tubular hoseand being engaged by said outer peripheral surface means of said tubularhose.
 8. A hose construction as set forth in claim 1 wherein saidcoupling has a rotatable nut means for fluidly coupling said hoseconstruction to other structure.
 9. A hose construction as set forth inclaim 1 wherein said coupling has an externally threaded end forcoupling to other structure.
 10. A hose construction as set forth inclaim 9 wherein said sleeve and said externally threaded end comprise aone-piece member.